Deformable Metal Elevation for Non-Slip Mounting Plate
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Solution Overview
Problem
Existing mounting plates for electrical devices on hat-shaped mounting rails experience slipping issues, especially with increasing device weight and vertically aligned rails, due to insufficient grip.
Innovation Solution
A mounting plate with two angled support webs, holders, and a metal elevation on its back that deforms to create high contact pressure, ensuring a non-positive and non-slip connection with the rail, made from an electrically conductive material to maintain constant contact pressure and resistance to temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the weight of the electrical device is increased, then the electrical device can handle higher loads, but the mounting plate slips on the mounting rail
Solution Approach 1:
The elevation is designed to deform under clamping force, changing its physical state from rigid to deformed, which adapts its contact surface to the contour of the support web and generates high contact pressure to prevent slipping
Solution Approach 2:
The elevation transforms from a static rigid component to a dynamic deformed component that adapts its shape during the clamping process, allowing it to conform to the support web contour and maintain optimal contact pressure
2Ease of manufacture
If a polymeric material is used for the elevation, then the manufacturing is easier, but the contact pressure decreases over time due to material relaxation
Solution Approach 1:
The material selection changes the physical and mechanical properties of the elevation, specifically choosing metal materials that do not undergo relaxation or creep, ensuring long-term stability of contact pressure
Solution Approach 2:
The mounting plate combines different materials strategically: the main body can be made of various materials while the elevation is specifically made of metal to provide stable contact pressure, creating a composite structure with optimized properties
3Reliability
If the contact pressure is increased to prevent slipping, then the grip on the rail is improved, but the mounting plate may break under excessive pressure
Solution Approach 1:
The elevation deforms to adapt its contact surface to the support web contour, distributing the clamping force more evenly and achieving high contact pressure without concentrating stress that would cause breaking
Solution Approach 2:
The deformable elevation acts as a cushioning element that absorbs and distributes the clamping force before it reaches the mounting plate structure, preventing stress concentration and potential breaking
4Reliability
If the mounting plate is made electrically conductive, then the electrical connection is improved, but the production cost increases
Solution Approach 1:
The mounting plate merges multiple functions into a single component: mechanical support, slip prevention through the deformed elevation, and electrical conduction, eliminating the need for separate grounding straps and reducing overall production cost
Solution Approach 2:
The mounting plate becomes a multi-functional component that simultaneously provides mechanical mounting, slip resistance through the elevation, and electrical conduction, replacing multiple separate components with one universal element
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides secure attachment of electrical devices to mounting rails, preventing slipping and maintaining contact pressure over time and temperature variations, eliminating the need for grounding straps and allowing use with various rail thicknesses.
Implementation Method 1
it and/or a part of the mounting plate connected to it deforms when the angled support web is clamped. As a result of this deformation, the contact surface of the elevation with respect to the support web is adapted exactly to its contour, with a high contact pressure acting in the direction of the support web even after the deformation
Implementation Method 2
the choice of material ensures that the deformation of the elevation and thus its contact pressure against the support web is almost unaffected by the temperature in a temperature range of up to 100°C
Data Source
Figure 1~2
Figure 3~3a
Figure 4
AI summary
The subject matter of the invention is a mounting plate (1) with fixing means for an electrical device and for a supporting rail (4), which is in the form of a top hat rail and is formed with two bent-back support struts (5), and with at least one holder (6), which is arranged on the rear side (3) of the mounting plate (1), with a bearing section, wherein an elevation (7) made of metal is provided on the rear side (3) for the purpose of clamping at least one bent-back support strut (5) against the bearing section of the holder (6). In order to connect the mounting plate to the supporting rail in a manner in which it is secured against slipping, the elevation (7) is selected in terms of its arrangement, geometry and dimensions and material properties in such a way that it itself is deformed and/or a part of the mounting plate (1) which is connected to it is deformed when the bent-back support strut (5) is clamped.